I spent four hours working on the right rear brake. Grrrr! Had a new rotor and pads in place, went to put the caliper back on and found out that the piston isn't pushed in far enough. I used a brake caliper tool and no matter how much I turn the thing it won't go in any further. It just spins and spins. I've tried removing the master cylinder cap and unscrewing the bleeder screw. Parking brake is also off. I've also tried pumping the brake pedal to push the piston back out and used the tool to push the piston back in but it still wouldn't go in far enough for the caliper to fit over the new pads and rotor. I got so pissed I put the old parts back on and called it a day. Four hours wasted!

Here's a picture of the caliper piston showing how much it still sticks out. Is it time for a new caliper?

That should fit over the pads and rotors in the position that it's in, it'll be tight but it should fit. If that still doesn't work try disconnecting the brake line from the caliper and twisting it in more, you'll have to bleed your brakes afterword though.

That caliper will not fit over new pads unless the piston is reset as shown in the first photo. You have to turn the piston clockwise while applying pressure to push the piston back into the caliper. The proper caliper tool to do that is shown in the second photo. You can purchase one at Harbor Freight tools or perhaps even borrow one from a chain auto parts store that loan out tools. Once the piston is reset, don't forget to position the indented recesses on the piston face so one of them aligns and fits into the small pin on the back of the in-board brake pad as shown in the third photo. Good luck. Refer to this link for additional details:

That should fit over the pads and rotors in the position that it's in, it'll be tight but it should fit. If that still doesn't work try disconnecting the brake line from the caliper and twisting it in more, you'll have to bleed your brakes afterword though.

Use a c-clamp and a little flat piece of metal. Is the piston broken or is that just the picture?

It's not broken.

Quote:

Originally Posted by 6-Speed

That caliper will not fit over new pads unless the piston is reset as shown in the first photo. You have to turn the piston clockwise while applying pressure to push the piston back into the caliper. The proper caliper tool to do that is shown in the second photo. You can purchase one at Harbor Freight tools or perhaps even borrow one from a chain auto parts store that loan out tools. Once the piston is reset, don't forget to position the indented recesses on the piston face so one of them aligns and fits into the small pin on the back of the in-board brake pad as shown in the third photo. Good luck. Refer to this link for additional details:

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